Ambrell Induction Heating
Ambrell Induction Heating
automotive manufacturing image

Automotive Manufacturing

Within the automotive industry, induction heating has been used in the manufacture of large-scale parts for the main body, engine, electrical, steering, fuel and exhaust systems. With the broad operating frequency range of our induction heating systems, we're able to heat parts of virtually any size. Larger parts such as camshaft gears are heated at lower frequencies while smaller parts such as flexible electrical circuits are effectively heated at higher frequencies.

Popular Automotive Manufacturing Application Notes

Click to read how induction heating can improve the efficiency, effectiveness and safety of your automotive manufacturing process.

Soldering a radio antenna

To heat a coaxial antenna assembly to 600°F within 2 seconds for a soldering application. The goal to improve on an existing procedure with a soldering iron which required 10 to 15 seconds.

Soldering flexible electrical circuits

Heat multiple joints on solar flex circuit strips to 500°F (260ºC) within ten seconds for a soldering application.

Shrink fitting aluminum pulley to insert inner bearing

A three turn helical coil is used to heat the aluminum pulley. The pulley is heated to 464 ºF (240 ºC) in 20 seconds to expand the inner diameter and then the inner bearing is inserted to form the completed part.

Shrink fitting an assembled wrist pin into a connecting rod

Induction heating provides more accurate control of heat vs a flame burner, it heats only the knuckle, not the whole part, it prevents discoloring due to lower temperature used and increases productivity due to repeatability & ease of operation. A foot pedal & timer is used.

Inserting a piston stop with o-ring into an oil pump assembly

Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing

Brass Inserts

Heating is to be accomplished within 5 seconds, and can be done in a helical coil since “pick and place” manufacturing is employed.

Heat the end of catalytic converter for weld testing

Heat the end of lorry catalytic converter exhaust system. The assembly must be held at target temperature for 200 hours, whilst the assembly is vibrated to test the weld strength

Heating lead battery terminal for removal (recycling)

A single turn helical coil is used for this heating application. The lead terminal is placed inside the coil and is heated for 20 seconds.

Simultaneously heating six wire bundles to strip varnish

Induction heating provides hands-free heating that involves no operator skill for manufacturing. A multi-position coil provides simultaneous heating for quicker production times.

Heating a motor prior to adding an injection molded part

Induction heating enables quicker process times with increased production rates versus a gas-fired oven. Ovens require long heat-up and cool-down times

Heating steel liners (engine head)

Precise direct heat to disengage the aluminium quickly and cleanly. The aluminium casing is recycled and reused thereby reducing scrap and cutting costs.

Heating of steel rivet ends (turbines)

Heating steel rivets prior to head forming

Case Hardening of Armature Shaft

A five turn helical coil is used to heat the gear end of the shaft to 1700ºF

Bonding Rear View Mirror Brackets to Windshield Glass

A unique four-over-four double wound pancake coil is used for the bonding application.

Curing Adhesive on Steel Motor Shaft for Bonding

A complex two coil system, shield and stud systems used to provide proper axial alignments of the shaft & coil while allowing the fixture to be open for removal of the shaft.

Heat a compacted litz wire bundle for stripping

A three turn helical coil is used for the wire stripping process. The litz wire bundle is placed in the coil for 3 seconds to strip the lacquer 0.75” (19mm) from the end of the bundle. The wire bundle is then scraped with a metal brush to remove the burnt lacquer.

Heat aluminum for brazing an automotive assembly

A multi turn pancake coil is used to heat the joint between the aluminum tubing and boss. The joint heats to temperature in 1.5 minutes and the braze ring melts forming a clean brazed joint.

Bonding Automotive Trim Vinyl Covering

Heating to 500°F is accomplished through the use of the unique coil; molding is continuously processed at a rate over 20 feet per minute.

Sealing a Nylon Shell for a fuel vapor Assembly

Filter modules are assembled on the fixture with ring gasket. Pressure is applied to the modules, modules are rotated and induction heating is started. After 10-12 seconds, heating is halted and the modules are removed from the fixture.

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About Induction Heating

Induction heating is a fast, efficient, precise and repeatable non-contact method for heating metals or other electrically-conductive materials. The material may be a metal such as brass, aluminum, copper or steel or it can be a semiconductor such as silicon carbide,carbon or graphite. To heat non-conductive materials such as plastics or glass, induction is used to heat an electrically-conductive susceptor, typically graphite, which then transfers the heat to the non-conducting material.

Read our 4-page brochure; learn more about how the science of induction technology can solve your precision heating problems. 

Read 'About Induction Heating'

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Induction Heating Work Coils

The work coil is the component in the induction heating system that defines how effective and how efficiently your work piece is heated.

Provide a little of your business contact information to read our informative brochure explaining the fundamentals of the induction work coils and their design.

 

Read 'Induction Heating Work Coils"

View more Automotive Manufacturing Application Notes

 

Soldering a radio antenna
Soldering flexible electrical circuits
Shrink fitting aluminum pulley to insert inner bearing
Shrink fitting an assembled wrist pin into a connecting rod
Shrink Fitting steel parts into an aluminum fuel pump housing
Fitting a cast iron rocker arm
Inserting a piston stop with o-ring into an oil pump assembly
Heat Staking brass inserts into plastic sub-assembly
Heating the end of catalytic converter for weld testing
Heating lead battery terminal for removal from plastic cover for recycling
Heating encapsulated ceramic thermostat for testing
Braze an end plug on a stainless steel car grill
Heating a motor prior to adding an injection molded part
Heating steel liners (engine head)
Heating of Steel Rivet Ends (Turbines)
Case Hardening an armature shaft
Curing Aluminum Car Moulding
Curing adhesive on rear view mirror brackets
Curing adhesive inside a steel motor shaft
Heat a compacted litz wire bundle for stripping
Heat aluminum for brazing an automotive assembly
Bonding vinyl trim
Sealing a Nylon Shell for a fuel vapor Assembly
Bonding rubber gaskets to a steel gas intake manifold
Shrink Fitting 2-inch thick steel cam shaft gears
Pre-heating a truck axle seam
Heat Staking steel studs into a plastic tail light
Heating engine valve heads
Hardening steel seat belt retractor gears
Heating Aluminum Auto Trim for Adhesive Curing
Curing adhesive on aluminum auto trim
Copper Brazing an oil suction assembly
Annealing steel regulator bases for fuel injection system
Atmospheric Brazing hydraulic hose assemblies

Brazing, soldering, molding, adhesive curing, annealing, hardening, heat staking metal-to-plastic, shrink fitting, bonding and many other processes all benefit from the many advantages offered by modern solid-state induction heating systems.

Induction offers:

  • Selective Heating
  • Maximum Repeatability
  • Faster Cycle Time
  • Pin Point Accuracy
  • Flexible Set Up
  • Reduced Emission
  • Increased Profitability
  • Improved User Interface
  • Reduced Scrap & Rework